Roofing Method and Apparatus

ABSTRACT

In an embodiment, a method includes applying a liquid plural component polymer to a sloped roof to form a protective surface that inhibits moisture seepage to the roof sheathing. In some embodiments, the plural component polymer may be a polyurea compound having a hardening time that is less than approximately 10 minutes. In some embodiments, one or more of the components may be aerated prior to application to the roof substrate. In some embodiments, one or more polystyrene panels may be affixed to the sloped roof prior to application of the liquid plural component polymer. Other embodiments are described and claimed.

BACKGROUND

Building roofs, including roofs of family dwellings, are oftenconstructed with shingles, e.g., “composition” shingles. Compositionmaterial may include a tar-impregnated fibrous base, e.g., fiberglass,and may be coated with sand-like or similar materials. As a result ofweathering and wear due to exposure to sunlight, heat, cold, andmoisture, composition shingles (“tiles”) degrade, becoming brittle andporous. Brittle and/or porous shingles can cause moisture leaks, and mayeventually become detached from the roof.

Improvements in roofing materials can increase roof life andeffectiveness to shield a house from weather elements such as moisture(e.g., rain, snow, hail, etc.), sun, wind, ambient temperature, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a representation of a roof, according to an embodiment.

FIG. 2A is a representation of a cross-section of a portion of a roof,according to an embodiment.

FIG. 2B is a representation of a cross-section of a portion of a roof,according to another embodiment.

FIG. 3 is a representation of a cross-section of a portion of a roof,according to another embodiment.

FIG. 4 is a flow diagram of a method of making a roof, according to anembodiment.

FIG. 5 is representation of a cross-section of a portion of a roof,according to another embodiment.

FIG. 6 is a flow diagram of another method of making a roof, accordingto another embodiment.

FIG. 7 shows representations of cross sections of roofs, according toother embodiments.

FIG. 8 is representation an apparatus that can be used in making a roof,according to another embodiment.

FIG. 9 is a flow diagram of a method of making shingles, according to anembodiment.

FIG. 10 is representation of a roof, according to another embodiment.

FIG. 11 is representation of a roof, according to another embodiment.

DETAILED DESCRIPTION

Methods and apparatus are presented to make a protective surface thatforms at least part of a roof of a structure. The protective surface maybe formed by applying a plural component polymer liquid to a roofsubstrate of a roof. In an embodiment, the non-aqueous based liquidincludes a polyurea compound that, upon application, solidifies toproduce a solid surface that adheres to the roof substrate. The pluralcomponent polymer liquid may have a fast hardening time, e.g., of theorder of seconds to minutes after application, permitting asubstantially uniform application to a sloped roof without thinning dueto, e.g., drift of the liquid (e.g., as a result of gravitationalforce). Other embodiments are described.

Referring to FIG. 1, shown is a representation 100 of a sloped roof,such as a roof of a building, e.g., a house, or another type ofbuilding. The roof may include a substrate 102, a coating 104, fasteners106, drip edge flashing 108, and rake edge flashing 110. A sloped rooftypically has a slope (e.g., rise over run) of 1/24 or greater. Moretypically a sloped roof has a slope of 1/12, and often sloped roofs haveslope of 3/12 or greater. Sloped roofs may promote runoff of moisture,e.g., rain, snow, etc., and may be a feature of houses such as familydwellings, etc.

The substrate 102 may include underlayment, sheathing, shingles, othersubstrate materials, and the substrate 102 may comprise wood, tar-basedcovering, and/or other covering materials. The coating 104 may be anon-aqueous material, such as a polyurea compound and/orpolyurethane-type material. The coating 104 may serve as a barriermembrane to protect the substrate 102 from moisture, sun, and other wearagents that may cause a breakdown of the roof, e.g., inability toprotect contents of the building from e.g., moisture, sun, and otherundesired external agents. In some embodiments, the coating 104 may beapplied in new construction, e.g., directly over roof sheathing (e.g.,plywood and/or oriented strand board). Additionally, the coating 104 maybe applied to an existing roofing assembly to protect the existingroofing assembly from, e.g., weathering agents, e.g. rain, wind, snowetc.

The drip edge flashing 108, rake edge flashing 110 and other flashing(not shown, including but not limited to flashing applied to conjoiningplanes of a roofing surface, and protrusions such as chimneys, plumbingvents, other vents, and other protrusions) may be integrated with otherportions of the roof. Integration of the flashing with the otherportions of the roof may be accomplished by, e.g., inclusion of thecoating 104 between the flashing 108 and the substrate 102, andapplication of plural component polymer material to the flashing afterthe coating 104 has been applied to the substrate 102 in a layered, or“sandwich-like” fashion, or by combinations thereof, and may be used, insome embodiments, as part of a sloped roof and/or as part of asubstantially flat roof (e.g., non-sloped roof having a slope of lessthan 1/12 and/or less than 1/24).

Referring to FIGS. 2A and 2B shown is a representation 200 of a portionof roof that is retrofitted, according to an embodiment. A sheathing 202may be affixed to members of a roof frame, e.g., to frame studs (e.g.,members (e.g., 2″×4″ or other dimensioned) that may be made of wood,metal, plastic, or another material). In an embodiment, underlayment 204may be affixed to the sheathing 202, the underlayment 204 typically madeof a malleable material such as felt, tar paper, a fibrous blanket-likematerial, or another type of covering. Fastened to the underlayment 204may be roof shingles 206, which may be made of wood, metal, concrete,tile, a composite material such as tar-impregnated fibrous materialcoated in aggregate (e.g., a granular, or sand-like material), or otherroofing materials, and may serve as an outer surface of the roof priorto a retrofit process that may include application of the pluralcomponent polymer to the outer surface.

In the retrofit process, a membrane layer 208, e.g., plural componentpolymer material, may be applied as a liquid that may polymerize to forma solid water-repellant surface. In an embodiment, the membrane may beapplied by, e.g., spraying the plural component polymer in liquid formonto exposed surfaces of the existing roof including the roof shingles206, and onto flashing material including a drip edge flashing 212,which may be affixed (as part of the existing roof and prior toretrofit) to the roof shingles 206 and to the sheathing 202. In anembodiment, a rapidly hardening plural component polymer liquid may beapplied to form the membrane, e.g., hardening (e.g., via polymerization)to occur in a time period (e.g., beginning at a time that the liquidleaves an application apparatus, e.g., spray gun) of several seconds toseveral minutes and less than approximately 10 minutes. By employing arapidly hardening plural component polymer (e.g., a polyurea compound),the layer applied to the roof may tend to have a more uniform thicknessover the extent of the membrane than, e.g. through use of a substancewith a long hardening time (e.g., one hour or longer) because the pluralcomponent polymer that forms the membrane will harden before significantdrift of the liquid occurs due to gravitational effects that wouldotherwise result in non-uniformity of membrane depth.

In an embodiment, after the membrane layer 208 is applied to theexisting roof outer surface, a drip edge flashing 214 and a rake edgeflashing 216 (shown in FIG. 2B) may be affixed to the roof structure.The drip edge flashing 214 and the rake edge flashing 216 may be madeof, e.g., flashing material such as a shaped metal or other shapedsolid, and may be affixed to the previously existing roof structure, themembrane layer 208, the roof shingles 206, the underlayment 204, and thesheathing 202 through use of e.g., mechanical fasteners such as nails,screws, other mechanical fasteners, or other attachment techniques. Thedrip edge flashing 214 and the rake edge 216 may serve to deflectmoisture away from an edge of a retrofitted roof surface formed by,e.g., the membrane layer 208, the roof shingles 206, the roofunderlayment 204, and the sheathing 202.

According to an embodiment, a portion of the plural component polymermay be sprayed onto the existent roof structure prior to installing thedrip edge flashing 214 and the rake edge flashing 216 (e.g., pluralcomponent polymer applied beneath each of the drip edge flashing 214 andthe rake edge flashing 216). After application of the plural componentpolymer to the existent roof structure, the drip edge flashing 214 andthe rake edge flashing 216 may be affixed, and additional pluralcomponent polymer may be applied to coat the drip edge flashing 214 andrake edge flashing 216. The additional plural component polymerapplication may further extend to cover a portion of the membrane layer208, which can result in the drip edge flashing 214 and the rake edgeflashing 216 being integrated within the (extended) membrane 208 andincluding the mechanical fasteners that attach flashing (drip edgeflashing 214 and rake edge flashing 216) to the sheathing 202.Sandwiching at least a portion of the flashing into the membrane 208 mayserve to anchor the membrane 208 to the roof assembly to prevent liftingby, e.g., wind or other weather elements. Integration of the flashing(drip edge flashing 214 and rake edge flashing 216) into the membrane208 may serve to protect the flashing from deterioration due to, e.g.,moisture and/or other weathering agents. In some embodiments, use of the“sandwich” technique to install flashing may be applicable to slopedroofs and to non-sloped roofs.

FIG. 2B shows another cross-sectional view 250, along a rake edge of theretrofitted roof of FIG. 2A, according to an embodiment. The rake edgeflashing 216 includes flashing material that is coated with the membrane208 on an outer portion of the rake edge flashing 216, and the rake edgeflashing 216 is partially “sandwiched” between portions of the membrane208 to protect otherwise exposed portions of the rake edge flashing 216from weather elements, e.g., rain, snow, etc. In some embodiments, useof a sandwich or partial sandwich technique to protect flashing andintegrate the rake edge flashing into the retrofitted roof may beapplied to sloped roofs and to non-sloped roofs. Note that theembodiments described herein are not limiting and additional embodimentsare contemplated.

Referring to FIG. 3, shown is a cross-sectional view of a roof 300,according to an embodiment. The roof 300 may include a frame 302 thatmay include a plurality of vertical studs and a plurality of roofsupport members e.g. joists and/or trusses that are affixed to thevertical studs and that form an underlying support structure. Affixed tothe roof support members may be a roof deck 304 that can includesubstantially planar sheathing material, such as wood or wood-basedmaterial e.g. oriented strand board (OSB), or other sheathing material.Underlayment 306 and roof shingles 308 may be affixed to the roof deck304 via, e.g. mechanical fasteners 316. The roof shingles 308 may haveconstituted an outer roof surface of the roof prior to a roof retrofit.The roof shingles 308 may be constructed of composition material (e.g.,tar and aggregate mixture, or other composition), wood, slate, concrete,earthen tile, metal, or another roofing material or combination thereof.

One or more panels 310 may be affixed to the roof shingles via, e.g.,mechanical fasteners 318 and/or adhesive. In an embodiment, the panels310 may be constructed from a polystyrene foam, or another solid plasticmaterial, and the panels 310 may be shaped prior to installation overthe roof shingles. For example, the panels 310 may be shaped to resembleone or more roof shingles, or another conventional roofing system suchas standing seam metal roofing, tile, slate etc. Shaping of the panels310 may increase marketability of a retrofit of the roof, because theshaped panels may provide the retrofitted roof with an appearance of aconventional shingle roof or other conventional roof shape. Similarityof the appearance of the retrofitted roof to a conventional shingle roofmay significantly enhance marketability of the retrofitted roof, wherethe roof is retrofitted according to embodiments presented herein.Pre-formed shaped panels (made from, e.g., polystyrene or othermaterial) may be used in formation of sloped roofs and non-sloped roofs,in some embodiments.

At least a portion of an outer surface of the panels 310 may be coatedwith a first membrane layer 320, which may be is situated at leastbetween the panels 310 and flashing 312 that may be affixed to theportion of the panels 310 and optionally to the shingles 308 and theroof deck 304 by, e.g. mechanical fasteners 314. A first layer 320 ofmembrane formed from a plural component polymer (e.g., polyurea) mayencase the flashing 312 and may promote adhesion of the flashing 312 toa second layer of membrane 322 (formed from the plural component polymer(e.g., polyurea), forming a structure that includes flashing 312 andmembrane 322. Mechanical fastening of the flashing 312 to the roof deck304 can serve to anchor the membrane layers 320 and 322 to the roof deck304, with the flashing 312 sandwiched between the membrane layers 320and 322. This sandwiching of the flashing 312 between the membranelayers 320 and 322 may prevent deterioration of the flashing 312 due toweathering agents that might otherwise directly contact the flashing.Additionally, the flashing and membrane in combination may prevent waterand/or other weathering elements from reaching any portion of the roofassembly that is beneath the membrane/flashing combination that includesthe membrane layers 322 and 320, flashing 312 and fasteners 314. Thefirst membrane layer 320 may partially or completely coat the flashing312, and may extend to at least the portion of other surfaces of thepanels 310. In an embodiment, the first membrane layer 320 may beapplied to the flashing 312 prior to affixing the flashing to the panels410. In another embodiment, the first membrane layer 320 may be appliedportions (e.g., outer surface of the panels 310), after which theflashing 312 may be affixed to the panels 310.

After the flashing 312 is affixed to the panels 310, the second membranelayer 322 may be applied to exposed portions of the panels 310 and toexposed portions of the flashing 312. In an embodiment, the secondmembrane layer 324 may be applied in a liquid form that hardens to forma barrier to protect underlying components from weathering agents suchas moisture, sun, etc. The first membrane layer and the second membranelayer may be a non-aqueous material such as a polyurethane, polyurea, orother plural component polymer compound that may be applied in liquidform and that hardens to form the second membrane layer 322. In anembodiment, the second membrane layer may be formed from a quicklyhardening (e.g., quickly polymerizing) material, e.g., having ahardening time of less than approximately 10 minutes from time ofapplication, and in some embodiments, having a respective hardening timeof less than approximately 2 minutes, and in some embodiments, having aneffective respective hardening time of less than approximately 30seconds.

After application of the second membrane layer 322, optionally anultraviolet blocking layer 324 may be applied to the second membranelayer, e.g., as a liquid substance that hardens to form anultraviolet-protecting surface that filters out or reflects ultravioletlight that may impinge on an outer surface of the ultraviolet blockinglayer 324. The ultraviolet blocking layer 324 may be a polyurethanecompound that can filter ultraviolet light and that effectivelywithstands weathering effects, e.g., moisture, heat, etc. over amulti-year life span that may be expected of the retrofit. The thirdmembrane layer 324 may also contain color pigments to color the roofsurface, which may provide may provide color (dark or light) thatreflects or absorbs heat, and may enhance the roof aesthetically. Thereflective or absorptive properties of the third membrane layer 324 mayresult in energy savings and may improve comfort in the interior of thebuilding, e.g., attic temperature. Use of multiple layers, e.g.,polyurea, polyurethane, and/or other plural component polymer layers,may be applicable to sloped roofs and to non-sloped roofs, in someembodiments. Note that the embodiments described herein are notlimiting.

Turning to FIG. 4, shown is a flow chart 400 of a method of making aroof, according to an embodiment. At block 402, a substrate roof outersurface is cleaned of loose debris. The cleaning may include sweepingdebris from the roof outer surface (e.g., via forced air, mechanicalsweeping/cleaning techniques, etc.). Additionally, the cleaning mayinclude surface preparation of the substrate roof outer surface, whichmay include, e.g., abrasion of the substrate roof outer surface through,e.g., sand blasting, surface preparation by chemical agents, or othersurface preparation techniques to ensure adhesion of a membrane layer tothe substrate roof outer surface. Continuing to block 404, preparationmay include removal of one or more sections of the substrate roof arenon-parallel to other portions of the substrate roof outer surface(e.g., not substantially co-planar with other portions of the substrateroof).

Advancing to block 406, a first membrane layer (e.g., a plural componentpolymer compound, e.g., polyurea) may be applied, in liquid form, to aperimeter strip of the substrate roof. In an embodiment, the applicationmay be through a spray technique, described herein. In an embodiment,the plural component polymer compound may have a relatively shorthardening time (e.g., of the order of one or more second, up toapproximately 10 minutes). In an embodiment, the perimeter stripincludes an outer strip of the substrate roof that is at least as wideas a flashing strip to be affixed to the substrate roof at perimeterportions of the substrate roof and may include including dormers andregions surrounding protrusions, e.g. vents, chimneys etc. In anembodiment, the perimeter strip has a longitudinal extent that is atleast twice a longitudinal extent of the flashing strip, so that whenthe flashing strip is affixed to the perimeter strip of the substrateroof the first membrane layer extends beyond the longitudinal extent ofthe flashing strip, providing a moisture barrier between the substrateroof and the flashing strip and allowing the flashing to be encasedbetween two layers of the sprayed membrane material.

Moving to block 408, the flashing strip may be affixed to the substrateroof at the perimeter strip, e.g. rake edges, drip edges, dormer edgesetc., through use of mechanical fastening techniques. Each section offlashing is to contact the first membrane and may be fastened to theunderlying roof via mechanical fasteners that pierce the first membraneto the substrate roof and roof decking.

Proceeding to block 410, a second membrane layer (e.g., a pluralcomponent polymer compound, e.g., polyurea) may be applied, in liquidform, to outer surfaces of the substrate roof and affixed flashing,e.g., via a spraying technique. The second membrane layer may harden toform a retrofitted roof outer surface that protects the underlyinglayers (e.g., substrate roof and flashing) from degradation due to,e.g., weathering agents, etc. Continuing to block 412, the secondmembrane may optionally be coated with a top coat (e.g., a pluralcomponent polymer compound, e.g., polyurethane) to protect the secondmembrane and substrate roof from, e.g., effects of ultraviolet light,and to provide reflectivity and color choice to enhance aesthetics ofthe retrofitted roof. In an embodiment, one or more to the membranelayers may have brief hardening times that counteract a tendency tonon-uniformity of layer thickness due to liquid drift, e.g., as a resultof gravitational effects. The method ends at 414. The method may applyto sloped roofs and also to non-sloped roofs, in various embodiments.

Turning to FIG. 5, shown is a cross sectional view of a sloped roofaccording to an embodiment. The roof may include a substrate that caninclude shingles 510 that may be made of a composition material such asa combination of petroleum-based tar and aggregate (e.g., sand), woodenshakes, slate shingles, etc. For example, the shingles 510 may haveserved as an exterior surface in a previous roof installation that isbeing re-roofed. Re-roofing may be warranted due to, e.g., moistureleakage, cracking of the shingles, missing portions of the shingles dueto, e.g., weathering agents such as moisture (e.g., rain, snow, ice,etc.), sun, wind, etc.

A membrane layer 512 that can serve as an outer layer of the roof may beformed from, e.g., a non-aqueous plural component polymer membrane,e.g., polyurea or another non-aqueous plural component polymer plastic.The membrane layer 512 may be applied as a liquid to the substrate, andmay subsequently harden to form an outer layer that is resistant toweathering agents such as moisture (e.g., rain, snow, ice, hail, etc.),and that is resistant to some weathering agents such as sun, wind, etc.The membrane layer may include a secondary outer layer 514 that can be acolor filter material to protect against, e.g., detrimental effects ofultra-violet light and/or other weathering agents. The secondary outerlayer 514 may be applied as a liquid and that hardens to form aprotective outer layer. For example, the secondary outer layer 514 maybe sprayed on as a liquid that can harden, e.g., by polymerization, orby a chemical process, e.g., through chemical reaction with atmosphere(e.g., oxygen). In one embodiment, the secondary outer layer 514 may bea polyurethane compound. Use of several polymer layers may be applicableto non-sloped roofs and to sloped roofs, in some embodiments.

As shown in the cross-sectional view, the roof may include a pluralityof layers including a roof sheathing 506 (e.g., plywood, oriented strandboard (OSB)), roof underlayment 508 (e.g., tar, felt, flexible plasticsheathing, etc.), roof shingles 510, non-aqueous hardened membrane layer(e.g., polyurea) 512, and optionally colored UV-filter layer 514 (e.g.,polyurethane). Flashing (not shown) may be installed after the membranelayer 512 is applied, and the flashing may be integrated into themembrane as described above.

Turning to FIG. 6, shown is a flow chart of a method to include anaeration agent (e.g., foaming agent) to a non-aqueous liquid to form amembrane layer of a roof, according to an embodiment. At block 602, theaeration agent may be added to one or more parts of a single orplural-component polymer liquid to be applied as a protective layer ofthe roof. For example, the plural-component plastic liquid may be anon-aqueous material, such as a polyurea. The aeration agent may bee.g., air, a gas such as nitrogen, oxygen, an inert gas such as argon,helium, etc., a gaseous compound such as nitrogen oxide (NO, NO₂, etc.),or another gaseous or volatile liquid material. The aeration agent mayserve to promote flow of the multi-component liquid, e.g., intointerstices of the layer to which the multi-component liquid is appliedto e.g., existing roof shingles, shaped panels that are applied to roofsheathing or existing roof shingles, or applied to another layer. Theaeration agent may be added to one or more of the components of theliquid, e.g., prior to application to an existing roof layer. Forexample, the aeration agent may be added in storage container(s) priorto application via e.g., a spray device such as a spray-gun. In anotherembodiment, the aeration agent may be introduced to the plastic liquidwithin the spray device. Moving to block 604, the plastic liquid, withaeration agent, may be applied to the previously installed roof layer,e.g., existing shingles, via the spray device. The method ends at 606.The method 600 may be applied to non-sloped roofs and to sloped roofs,in various embodiments. The aeration agent may change a mass density ofthe layer formed from the aerated liquid, and may promote thermalinsulation characteristics of the layer.

Turning to FIG. 7, shown are cross-sections of protective layers of aroof, according to several embodiments. In a cross-section 704, aprotective membrane, e.g., a plastic non-aqueous plural componentpolymer layer 704 such as a polyurea, is applied to a roof substrate702, such as roof shingles, shakes, shingles, or other existing rooflayer or roof sheathing. The polymer layer 704 has not been aeratedprior to application to the substrate 702. In another cross-section 706,the substrate 702 may be coated with a non-aqueous plural componentpolymer layer 706 that is aerated by, e.g., an aeration agent or afoaming agent, which may help to promote flow into interstices of thesubstrate 702, providing increased protection against weathering agentssuch as moisture. In an embodiment, the aeration agent causesapproximately uniform distribution of aeration bubbles (e.g., cavities)within the plural component polymer layer 706. In a cross-section 708,the substrate 702 is coated with a plastic non-aqueous plural componentpolymer layer 708 that is aerated by, e.g., an aeration agent. The layer708 may have a greater density of aeration bubbles, as compared with adensity of aeration bubbles in the layer 706. The greater density ofaeration bubbles may reduce the mass density of the layer 708 ascompared with non-aeration. A reduced mass density of the layer 708 can,e.g., promote flow in the interstices of a substrate that is uneven, hasrough surfaces, high density of surface un-evenness, when indicated topromote adhesion due to the composition of the substrate, throughempirical testing with the substrate surface, etc. Further, aeration ofthe layers 706 and 708 may promote thermal insulation of the roof. In anembodiment (not shown), several protective layers of varying aerationdensity may be applied successively, which may result in an increase inadhesion to the surface 702, and increased thermal insulation effect ofthe roof. Use of aeration in one or more plural component polymer layersmay apply to non-sloped roofs and to sloped roofs, in variousembodiments.

Turning to FIG. 8, shown is a diagram depicting an apparatus 800 toapply, e.g., a UV-protective topcoat layer as part of a roof retrofit orconstruction process, according to an embodiment. The apparatus 800includes one or more reservoirs 802 to store one or more membraneliquids or liquid components, e.g., to be applied to a roof substrate orunderlying membrane layer or layers. Liquid in the reservoirs 802 is tobe provided to a pump or pumps 804, which may be a compressor(s) orliquid pump(s) that can provide a selectable combination of ingredientsstored in the reservoirs 802. For example the reservoirs 802 may providetwo liquids that, upon combination on the substrate surface afterapplication by apparatus 800, combine to apply speckled or mottledcombination of different shades of color from the reservoirs 802, to beapplied to a roof surface. The pump(s) 804 may be programmable toprovide a selectable pressure and/or proportion of ingredients stored inthe reservoirs 802 that enables adjustment of color of the speckledcolor combination. For example, the reservoirs may include a pluralityof selectable colors to enable an operator to select a color mixture ofthe membrane (e.g., outermost layer) to be applied to a roof surface,such as an existing roof, or to a roof substrate. Feed lines 806 mayprovide the output of the pump(s) 804 to each of one or morecorresponding spray gun cylinders 814, each of which is to supply acorresponding ingredient to a respective spray gun seat and needleassembly 816 that in turn supply the ingredient to a corresponding tip818 with a corresponding spray orifice. The spray gun cylinders, seatand needle assemblies, tips and orifices may be included in a spray gunapparatus that includes a spray actuator 810 and handle 808 to enablethe user to apply a selectable combination of ingredients to the roofsubstrate (not shown). For example, the spray actuator 810 may enableselection of the combination of ingredients, selection of proportion ofeach ingredient in an application mix, and may enable addition ofaeration agent(s) (and/or foaming agents) prior to application to theroof surface. The resulting mixture may be sprayed onto the roofsubstrate in a spray pattern 812 that may be mechanically determined(e.g., selectable) by the user. The apparatus 800 and variations thereofmay be used in construction and/or retrofit of sloped roofs andnon-sloped roofs, in various embodiments.

Turning to FIG. 9, shown is a flowchart of a method of making roofshingles, according to an embodiment. At block 902, a fiberglass mat maybe formed from, e.g., a slurry of fiberglass fibers. Continuing to block904, the mat may be infused with a plural component polymer, such as apolyurea compound. Advancing to block 906, mineral particles (e.g.,aggregate or other granular material) may be applied to a first surfaceof the infused mat that is to serve as an outer surface. Moving to block908, an adhesive, e.g. petroleum-based tar or other heat sensitiveadhesive, may be applied to a second surface of the mat, so that whenaffixed to a roof substrate, the adhesive can cause adhesion to the roofsubstrate due to heat absorption from, e.g., solar rays. Proceeding toblock 910, the treated mat is shaped to form a finished shingle. Themethod ends at 912.

Turning to FIG. 10, shown is a cross-sectional diagram of a roof 1000,according to an embodiment. The roof 1000 includes a roof substrate1002, shaped panels 1004, e.g., shaped foam such as a polystyrene foam,fasteners 1006, e.g., mechanical, adhesive, or other fasteners to fastenthe shaped panels 1004 to the roof substrate 1002, protective membrane1008 such as a non-aqueous plural component polymer membrane applied inliquid form that can harden to form a moisture-resistant layer,optionally including a color filter layer, e.g., an ultraviolet filterlayer, and an integrated edge flashing 1010 that may be sandwichedwithin the protective membrane 1008, according to embodiments describedherein. Additionally, a plant growth medium 1012, e.g., soil, sod, peatmoss, etc., may be placed above the protective membrane 1008, e.g.,within one or more depressions in the shaped panel 1004. The plantgrowth medium 1112 may enable the roof to support growth of plantsincluding edible vegetation, which may provide a source of food, andother benefits such as roof run off water management, and otherenvironmental benefits attributed to “green roof technology. Such “greenroof technology” may be especially useful in urban applications whereagricultural space is limited, and this embodiment extends a concept ofplanted green roofs to sloped roof structures.

Turning to FIG. 11, shown are roofs of two structures. A first structure1110 has a conventional roof with a plurality of vents 1102, which aretypically installed to prevent dry rot and other deleterious effects ofmoisture seepage into an attic due to porosity of the roof.

A second structure 1120 has another roof including a membrane layeraccording to embodiments such as shown in FIGS. 1 and 2, and includesfewer vents 1104 than in the conventional roof of the first structure1110. The second structure 1120 may have fewer vents than the firststructure 1110 due to protection against moisture seepage provided bythe protective membrane that is a non-aqueous plural component polymermaterial, such as a polyurea compound, and that can be applied in liquidform that hardens rapidly after application. Embodiments may employrapid hardening compounds including plural component polymer materialsthat harden in a temporal range of several seconds to several minutesafter application. Such rapid hardening materials may be suitable forapplication to sloped roofs, because the material will not significantlyshift (e.g., slide downward) before hardening, and so substantialuniformity of thickness is more easily achieved than with use of amembrane material having a long hardening time, e.g., in excess of 15minutes.

Fewer vents can translate to energy savings due to less heat needed incold weather, and less air conditioning needed in warm weather. Awater-resistant membrane thus permits a reduction in building envelopeventing, with consequent energy savings.

Embodiments presented herein may be applicable to sloped roof systems,and to non-sloped roof systems. While the present invention has beendescribed with respect to a limited number of embodiments, those skilledin the art will appreciate numerous modifications and variationstherefrom. It is intended that the appended claims cover all suchmodifications and variations as fall within the scope of the presentinvention.

What is claimed is:
 1. A method comprising: applying a plural componentpolymer liquid to a sloped roof, wherein the plural component polymerliquid hardens to form a first membrane layer that inhibits seepage ofmoisture to the sloped roof.
 2. The method of claim 1, wherein thesloped roof has a slope of at least approximately one twelfth ( 1/12).3. The method of claim 1, wherein the liquid comprises a polyureacompound that, after application, solidifies and adheres to a roofsubstrate.
 4. The method of claim 3, further comprising including afoaming agent in the liquid prior to applying the plural componentpolymer liquid to the sloped roof, wherein upon application the foamingagent is distributed substantially uniformly within the first membranelayer.
 5. The method of claim 1, wherein the roof substrate includes aplurality of layers including a polystyrene layer.
 6. The method ofclaim 1, further comprising applying a second plural component polymerliquid to the solidified layer to form a second membrane layer, whereinthe second membrane layer has a different mass density than the firstmembrane layer.
 7. The method of claim 1, wherein the plural componentpolymer liquid has a hardening time that is less than approximately 10minutes.
 8. The method of claim 1, wherein the plural component polymerliquid has a hardening time that is less than approximately 1 minute. 9.An apparatus comprising: a roof comprising one or more plastic panelsaffixed to a roof substrate; and a first plural component polymer thatis applied to one or more of the plastic panels, wherein the pluralcomponent polymer hardens to form a moisture-resistant coating.
 10. Theapparatus of claim 9, wherein the one or more plastic panels comprisepolystyrene.
 11. The apparatus of claim 9, further comprising one ormore flashing strips attached to a peripheral portion of each of theplastic panels, wherein each flashing strip is at least partially coatedwith the polymer coating prior to attachment.
 12. The apparatus of claim9, wherein the plural component polymer comprises a polyurea compound.13. The apparatus of claim 9, wherein the plural component polymer hasan associated hardening time that is less than approximately 10 minutes.14. The apparatus of claim 9, wherein the plural component polymer hasan associated hardening time that is less than approximately 1 minute.15. The apparatus of claim 9, wherein the plural component polymerincludes an aeration agent prior to application to the one or moreplastic panels.
 16. A system comprising: a first membrane layercomprising a first plural component polymer that is applied to at leastat a first portion of a perimeter of a roof substrate; one or moreflashing members, each flashing member affixed to the first membranelayer along a respective portion of the perimeter of the roof substrate,wherein the first membrane layer is at least partially situated betweena first respective surface of each flashing member and the roofsubstrate; and a second membrane layer comprising a second pluralcomponent polymer coating affixed to at least a second surface of one ofthe one or more flashing members.
 17. The system of claim 16, whereinthe first plural component polymer comprises a polyurea compound. 18.The system of claim 16, wherein the first plural component polymer has ahardening time that is less than approximately 10 minutes.
 19. Thesystem of claim 16, wherein the second plural component polymercomprises a polyurea compound.
 20. The system of claim 19, wherein thesecond membrane layer is applied to an extended portion of the firstmembrane layer, wherein the first membrane layer and the second membranelayer substantially cover the roof substrate.